GTxLGetStart

GTxL GERBERcutter 

®

GETTING STARTED

Copyright © 1999 by Gerber Technology, Inc. All rights reserved. This document may not be reproduced by any means, in whole or in part, without the written permission of the copyright owner. This document is part of the proprietary articles furnished to document Gerber Technology’s GTxL GERBERcutter®. In consideration of the furnishing of the information contained in this document, the party to whom it is given assumes its control and custody and agrees to the following: 1. The information contained herein is given in confidence and any part thereof shall not be copied or reproduced without the written consent of Gerber Technology, Inc. 2. This document or the contents herein under no circumstances shall be used in the manufacture or reproduction of the article shown and the delivery shall not constitute any right or license to do so. The information contained in this document is subject to change without notice. Gerber Technology, Inc., its subsidiaries and affiliates shall not be liable for errors in this documentation or for incidental or consequential damages in connection with furnishing, or  use of this material. COMMAND, G (stylized logo), GERBER BRISTLE SQUARE, GERBERcutter, GERBERmover, Knife Intelligence, and MARKAMATIC are registered trademarks of  Gerber Technology, Inc. AccuMark, AccuPlot, Booster PAK, GERBERmarker, GERBERplanner, GERBERsaver, GERBERspreader, IMPACT, MicroMark, and POWER Processor are trademarks of Gerber  Technology, Inc. Windows NT is a registered trademark of Microsoft Corporation. Adobe and Acrobat are registered trademarks of Adobe Systems Incorporated. Other company names, brand names, and product names mentioned in this book are recognized as trademarks or registered trademarks of their respective companies.

Gerber Technology, Inc. 24 Industrial Park Road West Tolland, CT 06084 USA Printed in USA 12/99 Document Number: 86727000

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Contents  Safety Precautions Dangerous Procedure Warnings................................................................vii  vii  Do Not Perform Maintenance Alone........................................................vii  Live Circuits ............... ................. ................. ................. ................. ..........vii  Turn Off Power Before Maintenance.......................................................viii  viii  Circuit Breakers/Switches for GTxL GERBERcutter ........................viii  Laser Origin Light ................. .................. .................. ................. ...............ix   Additional Precautions .................. .................. .................. .................. ......ix  Moving Machinery..............................................................................ix  Replacing Parts..................................................................................ix  Knife Blade.........................................................................................ix  Clothing............................................................................................... x  Compressed Air ................ .................. ................. ................. ..............  x  Lint ......................................................................................................  x  Equipment Training.............................................................................  x  Do Not Operate in an Explosive Atmosphere..................................... x   x  Use Caution When Handling the Monitor ........................................... x   x 

Information You Need to Know What information is available?.....................................................................1 Where is it?................................................................................................1 C-200MT Online Help and Release Info.............................................1  Available Documentation on Desktop or CD ........... .................. ......... 2 Glossary of Terms...............................................................................2 Viewing Documentation.............................................................................2  Acrobat Reader and PDF Format ................ ................. ................. .....3 ..... 3 Printing Documentation ................ .................. .................. .................. ....... 3 Conventions Conventions ................... ............................. ................... ................... .................... ................... ................... ................... ................... .............3 ...3 Customer Support .........................................................................................4

GTxL GERBERcutter System GTXL GERBERcutter................................................................................5 Major Subsystems ..............................................................................6 C-200 Cutter Controllers ...............................................................................6 Communication Between Components ..............................................6 Cutting Table .............. ................ ................ ................ ................ ................ ....7 .... 7 Cutting Table Components — GTxL...................................................8 Cutting Table Dimensions Dimensions ................. .......................... .................. .................. ................... ................... .................. ..........8 .8 Cutting Cutting Table Dimensions Dimensions — GTxL ................. .......................... .................. .................. .................8 ........8 Cutting Head and Beam Assembly Assembly .................. ........................... .................. .................. .................. ..............9 .....9 Cutter Work Surface..................................................................................9 BRISTLE SQUARES in Slats for GTxL ..............................................9 Vacuum Assembly...................................................................................10 Diagram of Vacuum Flow..................................................................10 Vacuum Vacuum System System — GTxL .................. ........................... .................. ................... ................... .................. ..........10 .10 Limit Switches..........................................................................................11 Limit Switch Configuration — GTxL..................................................11 Operator Controls ................ ................. ................. ................ ................. .....12 ..... 12 Circuit Breakers.......................................................................................12 Circuit Breaker Configuration — FEP Power....................................12 Circuit Breaker Diagram — GTxL ................. ................. ................. ..13

Contents

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Beam Control Panel ................................................................................14 Beam Control Panel — GTxL ...........................................................14 BCP Switches ...................................................................................14 Feed Rate Control.............................................................................15 Operator Console ................. ................. ................. ................. ................ 16 Typical Components .................. ................... .................. .................. 16 EStop and CTOT Control Panels......................................................17 CTOT Auto Enable............................................................................17 CTOT Jog...........................................................................................17 EStop Switches and Plungers .................. .................. ................... ..........18 Emergency Stop ...............................................................................18 EStop Plungers .................. ................. .................. .................. .......... 18 EStop Switches.................................................................................18 EStop Locations — GTXL.................................................................19 Material Advance Controls .................................. .................. ................. .19 Material Advance Controls — GTxL .................................. ............... 20 Presser Foot Adjust.................................................................................20  Air Pressure Gauge ............ ................. ................................. ............ 20 Lateral Drive Controls..............................................................................21 Typical Controls ................................................................................21 Lateral Drive Controls — GTxL.........................................................21 Options for GERBERcutter Systems ......................................................... 21 Lateral Drive Option.................................................................................22 Right Side Option ....................................................................................22 Conveyorized Take-off Table (CTOT).....................................................22 Resealer Option.......................................................................................22 POWER Processor..................................................................................23  AccuMatch .................. ................. ................. ................. .................. ........23 Hardware...........................................................................................23 Software............................................................................................23 Drill Options ................................. ................. .................. ................. ........24 Drill Options — Electric .................................. ................. .................. 24 Bristle Cleaner Options............................................................................24 Bristle Cleaning — Manual Vacuum ................................... .............. 24 Bar Code Reader.....................................................................................24

C-200MT Software for GTxL Software Installation....................................................................................25  Accessing C-200MT Program ................. .................. ................. ............. 25 C-200MT M ain Cutter Control Screen ........................................................26 Menu Bar ................. ................. .................. ................. ................. ........... 26 Tool Bar ................. .................. ................. ................. .................. ............ 27 Settings Options ................................. .................. .................. ................. 27 Gauges ................. ................. .................. ................. ................. .............. 27 Vacuum Level Gauge .......................................................................27 Knife Speed Gauge...........................................................................27 Cut Speed Gauge .............................................................................28 Knife Wear Gauge ............................................................................28 Feed Rate Slider......................................................................................28 Percent Complete Gauge........................................................................28 Two Line Output Display .................................. .................. .................. ...28 Cut File Information Button......................................................................29 System Setup Button...............................................................................29 Queue Information Button .................................. .................. .................. .29 File Display Area .....................................................................................30 File Display Options ................................... .................. .................. ...30

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Contents

Piece Colors in File Display Area .....................................................30 Status Bar................................................................................................30

Basic Concepts Direction and Location ................................................................................31 Ends and Sides .......................................................................................31 X, Y, and C-axes .....................................................................................32 Origin.............................................................................................................33 Bite Feeding..................................................................................................35

Basic Cutting Spreading Material.......................................................................................37 Basic Cutting................................................................................................38 Turning on the Cutter ..............................................................................39 Enabling Servo Power.............................................................................39 Initializing the Cutter................................................................................40 Positioning the First Bite..........................................................................40 Selecting a Setup ....................................................................................41 Opening a Cut File/Marker ................. .................. ................. ................. .42 Default Directories/Storage Areas ....................................................42 Changing AccuMark Parameter Tables............................................43 Cutter Parameter Table Editor..........................................................45 Using Rerun.............................................................................................47 Turning on the Vacuum ................. .................. .................. .................. ....47 Positioning the Laser Light .................. ................. .................. ................. 48 Setting the Marker Origin ........................................................................48 Selecting Cutting Speed..........................................................................49 Turning on the Knife Motor......................................................................49 Processing a Cut File/Marker..................................................................49 Trim Cut...................................................................................................50 Exiting the Program.................................................................................51

Recovery Before Using Recovery Commands........................................................53 Restore State...........................................................................................54 Restoring State Manually..................................................................55 Piece Search ................................. ................. ................. .................. ......55 Piece Recut ................. ................. ................. .................. ................. .......56 Restore Origin .........................................................................................56 Bite Search ................................. ................. .................. ................. ......... 57

Working with Parameters Parameter Manager......................................................................................59 Changing Parameters..................................................................................60 Categories of Parameters ...........................................................................60

Optimizing GERBERcutter  Maintenance .................................................................................................63 Applications..................................................................................................63 Diagnostics/Error Messages.......................................................................64 Beam Squareness...................................................................................64 Customer Support .......................................................................................64

Glossary Index Operator Controls Chart — GTxL

Contents

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Contents

Contents

vii 

Safety Precautions  Dangerous Procedure Warnings Warnings precede potentially dangerous procedures throughout this manual. Instructions contained in warnings must be followed. You also should employ all other safety precautions that you deem necessary for safe operation of the equipment in your operating environment.

WARNING!

Failure to follow these safety precautions could result in injury or death.

Do Not Perform Maintenance Alone Do not perform any maintenance on the equipment unless another person that can render first aid and resuscitation is present.

Live Circuits High voltages exist inside the C-200 controller vacuum/electric and electronics enclosure(s). The exact number of enclosures and their locations, depend on the GERBERcutter model. There are no operator-serviceable parts in these enclosure(s) . Two power cables enter the primary vacuum/electric enclosure: a three-phase cable for the vacuum generator system and a single-phase power  cable for the C-200 controller. Both power cables must be disconnected before it is safe for trained, maintenance personnel to work within the enclosure. There must be a main disconnect that meets local electrical codes for each power  supply. Primary Enclosure

Safety Precautions vii 

Turn Off Power Before Maintenance Depending on your GERBERcutter, circuit breaker(s) and/or a switch located outside of the vacuum and electric enclosure(s) allow you to shut down power to the FEP (or PC), vacuum system, C-200 cutter controller, servo motors, and conveyor. To prevent accidental start-up, always turn off power as directed  before doing any maintenance.

Circuit Breakers/Switches for GTxL GERBERcutter  Before performing maintenance on controller, servo motors, or conveyor , turn off power at the circuit breaker (CB1) at the electronics enclosure located below the operator console (shown). Before performing maintenance on vacuum system, turn off power at the circuit breaker  (CB1) below the operator console.

Circuit Breaker  CB1

viii Safety Precautions

To turn off all power to the cutter, turn off   power the switch (SW1) and circuit breaker  (CB2) at the vacuum/electrics enclosure located the end of the table (indicated on  previous page).

Laser Origin Light The origin light in the cutter head uses a laser light that points toward the cutting surface. When viewed as intended (by looking at the dot projected on the material to be cut), the laser should pose no hazard to operators. However, the origin light is a Class IIIa laser product, with a peak power of 5 mW at a wavelength of 670 nm. Never look straight into the light source of this laser   beam; doing so may cause temporary, or even permanent, damage to your eyes. Direct, bright reflections from the laser may also be harmful. Remove all highlyreflective material (such as jewelry and mirrors) from the cutting surface before turning on the origin light. Turn off the origin light before performing any maintenance on the GERBERcutter.

WARNING!

Use of controls or adjustments or performance of  procedures other than those specified herein may result in hazardous radiation exposure.

Additional Precautions Moving Machinery Keep hands away from the Resealer and other moving machine parts to avoid  personal injury. Make sure there is no one else near the table when you are operating the GERBERcutter.

Replacing Parts Report any broken or missing parts to your Field Service representative. Because of the danger of introducing additional hazards, do not install substitute parts or   perform any unauthorized modification of the equipment.

Knife Blade The knife blade is very sharp. Be extremely careful when working near the knife  blade.

Safety Precautions ix 

Clothing Loose-fitting clothing, dangling neck chains and ties, loose jewelry, and long hair can be a hazard when working around machinery.

Compressed Air  Always use caution when using compressed air. Never use compressed air to  blow lint and dust off clothing or skin.

Lint Avoid breathing in lint when changing the table and stack filters. Wear a mask  suitable for this purpose.

Equipment Training  Never attempt to operate this machinery unless you have received formal training to do so.

Do Not Operate in an Explosive Atmosphere Use extreme caution when handling flammable liquids such as cleaning solvents. Do not operate the equipment in the presence of flammable gases or fumes.

Use Caution When Handling the Monitor  The monitor on the operator console may be a cathode ray tube (CRT). Breaking a CRT could cause it to implode and scatter glass fragments at a high velocity. To prevent CRT implosion, avoid rough handling or jarring of the equipment. Other models use a flat panel screen monitor.

 x Safety Precautions

Information You Need to Know  What information is available? The GTxL GERBERcutter system includes hardware, electrical, and software components. Documentation for operating and maintaining the GERBERcutter  is available on your computer or from CD in the form of online help for the C-200MT software and in PDF format. This means that information is available to you whenever you need it. The next sections explain: •

Where information can be found

•

How to access this information

•

How to print out information

•

How to get customer support

Where is it? See the following sections to locate specific information.

C-200MT Online Help and Release Info The C-200MT software program provides several ways to get help when working with the current release.

Note:

All information in the C-200MT online help is also available in the C-200MT Software User’s Guide.

To get help on a C-200MT function

1. Choose a C-200MT menu and use the pointing device or Down arrow key to highlight the command. 2. Press the F1 key to display the appropriate Help topic. To get help on a specific parameter 

1. In Parameter Manager, highlight a parameter. 2. Press F1.

Information You Need to Know

1

To view information for current release

1. From the Help menu, click Index. 2. Make sure the Contents page is displayed. 3. Then select the New Features for (current version number) or  Limitations topics.

Available Documentation on Desktop or CD Documentation for your GERBERcutter hardware and software is now delivered in online format on CD. This means that specific information can be viewed onscreen, searched for, and printed as you need it. Some documentation for your  cutter was installed on your computer during the C-200MT software installation and is available by double-clicking the Gerber Documentation icon on your  Windows desktop. Additional documentation available on CD: •

C-200MT Software User’s Guide

•

GTxL GERBERcutter System Service Manual 

•

GTxL GERBERcutter Application Manual 

•

 NT Quick Reference Guide

•

Service drawings

•

Parts information Note:

The CD allows you to view and print information at another PC. For hints on printing see a later section in this chapter.

Glossary of Terms See C-200MT online help or C-200MT Software User’s Guide for a complete glossary of terms related to the GERBERcutter.

Viewing Documentation To view documents from Windows desktop

1. In the C-200MT program, click on the middle button (marked by two  boxes) in the top left corner of the main cutter screen. This does not shut down the C-200MT program.

2  Information You Need to Know 

2. On the Windows desktop, double-click on the Gerber Documentation icon. 3. Double-click on the icon for the PDF file you want to view. The reader  opens first and then the document displays. 4. From the tool bar, use the buttons marked with arrows to turn pages. Click the button marked with binoculars to search for a specific item. To view documents from CD

1. Use Windows Explorer to locate the PDF file you want to view. 2. Double-click on the file. The reader opens first and then the document displays. 3. From the tool bar, use the buttons marked with arrows to turn pages. Click the button marked with binoculars to search for a specific item.

Acrobat Reader and PDF Format GERBER Technology, Inc. now provides many documents and service drawings in PDF format. A document in PDF format is displayed in Adobe Acrobat Reader. If not already installed on your cutter, this viewer can be installed from the C-200MT Software CD.

Printing Documentation If you prefer to print out information and your cutter is not networked to a  printer, you can take the CD to another PC that does have access to a printer.

Note:

All information in the C-200MT online help is also available in the C-200MT Software User’s Guide.

To print from a PDF document

1. Follow the instructions for opening a PDF document from CD. 2. From the File menu, select Print. You can print one page or all pages.

Information You Need to Know

3

Conventions The following conventions are used throughout this manual: •

Bullets at the beginning of a section tell you what is covered in that section. Bullets also list a group of related items. Bullets in a procedure lists the types of input from you needed by the C-200MT program.

−

Bold type highlights important information. In procedures, selections to mak e with a pointing device or keyboard keys to press are bolded. In text, information that you need to consider first is bolded.

Shortcut keystrokes, such as Marker/Open, are underlined. Text that you need to type or message prompts look like this.

Note:  Notes contain important or helpful information.

CAUTION:

Cautions appear before procedures that could cause damage to equipment if not performed correctly.

WARNING!

Warnings tell you when you must follow a specific procedure or practice to avoid personal injury or death.

Customer Support If a problem still exists after troubleshooting, call Gerber Field Service Engineering for assistance. In North America, call Customer Support 800-999-1448. Outside North America, call your local service office. Have the following information ready when you call:

4

•

GERBERcutter you are using

•

Any special equipment or software you are using, such as the drill, resealer, or bar code reader option

•

Software packages you are using; include the software version numbers

•

Equipment number, if available

Information You Need to Know 

GTxL GERBERcutter System  The GERBERcutter is a computer-controlled cutting system that automates the entire cutting process, replacing hand-held cutters, templates, and patterns. Instead of patterns, the GERBERcutter uses computer data files, called cut files, or markers to guide its knife. These files are generated on marker making systems such as AccuMark ™ or MicroMark ™. Computer-aided accuracy means accurate notches and pieces, so that little time is wasted matching parts during sewing operations.

GTXL GERBERcutter  The GTxL cutter was designed to meet the need for producing small, lot-sized orders at the lowest cost per unit. It allows your company to respond quickly to the requirements of a low inventory environment. The GTxL offers the benefits of lower operating costs, short set-up time, high reliability, and modular design. The GTxL cuts plies with a compressed height up to 2.5 cm (1 in.). It is suitable for apparel industry applications, such as ladies fashion, suits, lingerie and sportswear, as well as automotive industry applications. The footprint of the GTxL cutter is small compared to the actual cutting surface, so that more work can be performed in a smaller area of your factory.

GTxL GERBERcutter System 5 

Major Subsystems A GERBERcutter has major subsystems that work together to cut material. These subsystems are: •

C-200 cutter controller 

•

Cutting table

•

Operator controls

C-200 Cutter Controllers Your GERBERcutter uses electronic and software components that work  together to run the cutting table. This command center of the GERBERcutter, collectively known as the C-200 cutter controller, includes the following components: •

Motion control computer (MCC) or controller board

•

Front End Processor (FEP) or PC

•

C-200MT cutter software Note:

The actual C-200 cutter controller components used to run your GERBERcutter depend on the cutter model and date of   purchase.

Communication Between Components The FEP, or PC, lets you communicate with the GERBERcutter by means of the C-200MT cutter software. It sends your instructions and cut file data to the MCC controller board, which tells the cutting table how to cut material. As cutting  progresses, the MCC board communicates the results back to the FEP, or PC.

FEP or PC w/ cutter software

6

GTxL GERBERcutter System

MCC Board

Cutting Table

Cutting Table The cutting table cuts material according to instructions from the C-200 cutter  controller. All GERBERcutter systems have these major parts: •

Table — varying heights, widths, and lengths

•

Cutter head and beam assembly

•

Beam control panel

•

Work surface

•

Vacuum assembly

•

Limit switches

•

Material advance controls

Other components may be standard or optional, depending on the GERBERcutter model. •

Mast

•

Exhaust stack 

•

Conveyor 

•

CTOT

•

Resealer 

•

Lateral drive controls

•

Lay puller 

GTxL GERBERcutter System 7 

Cutting Table Components — GTxL

Cutting Table Dimensions GERBERcutter systems are available with a variety of table dimensions to meet your production needs. Depending on the GERBERcutter model, there are several height, width, and length dimensions available.

Cutting Table Dimensions — GTxL Height

75 cm (29.5 in.) 80 cm (31.5 in.) 86 cm (34 in.) 91 cm (36 in.)

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GTxL GERBERcutter System

Width

1.7 m (67 in.)

Length

1.8 m (71 in.)

Cutting Head and Beam Assembly The cutting head and beam assembly cuts material by moving a reciprocating knife across the work surface. The assembly responds to commands from the C-200 cutter controller. The cutter head holds the knife that both reciprocates and turns to cut corners, curves, and notches. The cutter head moves across the width of the cutting table on a beam. The beam also travels the length of the cutting table. By combining these movements, the GERBERcutter accurately cuts complex patterns. A laser origin light on the cutter head lets you position the knife to start cutting at the right place. To do this, the origin light shines a point onto the material. The beam control panel is a terminal that lets you control the GERBERcutter  from the cutting table. See Beam Control section of this chapter.

Cutter Work Surface The work surface holds material for cutting. The actual cutting surface is made of Gerber BRISTLE SQUARES . Each bristle square has small holes in its  base. When you apply vacuum to the cutting table, air passes through these holes to hold down the material. Depending on your GERBERcutter model, the BRISTLE SQUARES fit into conveyor slats or plastic grids.

Note:

Bristle cleaner options are available for your GERBERcutter.

BRISTLE SQUARES in Slats for GTxL

GTxL GERBERcutter System 9

Vacuum Assembly The GERBERcutter uses vacuum to hold material firmly on the work surface during cutting. To supply vacuum, the cutter has a vacuum motor and generator  linked by belts or by a coupling. Depending on the GERBERcutter you  purchased, the vacuum motor and generator may be: •

Built-in at one end of the GERBERcutter 

•

Mounted externally and connected by duct to the GERBERcutter 

Diagram of Vacuum Flow

Vacuum System — GTxL Your GERBERcutter has a powerful, high efficiency centrifugal vacuum generator with diffused, under table, exhaust system. The sealed vacuum motor  does not require lubrication.

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GTxL GERBERcutter System

Limit Switches Limit switches set limits for how far the cutter head and beam can move on the cutting table in the +X, -X, +Y, and -Y directions. Each limit switch is located at a strategic point on the beam, beam control panel, or end cap cover and is activated by a corresponding magnet, or small metal plate, specifically placed on the cutting table. Example: A limit switch, located on the operator side of the work surface, limits cutter head movement by sensing when it has reached the home position. The C-200 cutter controller would not allow further cutter head movement in this direction.

Limit Switch Configuration — GTxL

GTxL GERBERcutter System 11

Operator Controls Operator controls let you give commands to your GERBERcutter and respond to system messages. These controls are: •

Emergency stop (EStops) switches and plungers

•

Circuit breakers

•

Beam control panel

•

Operator console

•

Material advance controls

•

Lateral drive controls (optional)

See the following sections and the chart at the end of this Getting Started manual.

Circuit Breakers Depending on your GERBERcutter, circuit breaker(s) and/or a switch located outside of the vacuum and electric enclosure(s) allow you to shut down power to the FEP (or PC), vacuum system, C-200 cutter controller, servo motors, and conveyor. Depending on the GERBERcutter model, there may be one or more enclosures located at the end of the cutter or on a separate table along side the cutter. See Safety Procedures section of this manual.

WARNING!

Do not turn circuit breakers inside of the vacuum and electric enclosure(s) on or off. High voltages exist within these enclosure(s) and inside the controller board. Never perform any work inside the vacuum and electric enclosure(s). There are no operator-serviceable parts inside.

Circuit Breaker Configuration — FEP Power  Factory Power  220V

A for FEP or PC, controller, servo motors, conveyor 

Factory Power  Voltage varies by model

B for vacuum system

12

GTxL GERBERcutter System

C to controller, servo motors, conveyor 

Circuit Breaker Diagram — GTxL

GTxL GERBERcutter System 13

Beam Control Panel The beam control panel (BCP) lets you control the cutter head, beam, and certain table functions from the cutting table. The BCP is mounted on the operator’s side of the beam.

Note:

Icons on several tool bar buttons correspond to those on switches on the beam control panel at the cutter. For  GERBERcutters with colored icon keys on the keyboard, these also are identical to icons on the tool bar buttons.

Beam Control Panel — GTxL Switches may be of the any of these types: button, turn, flip, or joystick.

BCP Switches

14

•

Knife — Turns the knife motor on or off.

•

Joystick — Moves (slews) the cutter head and beam in the direction of  the arrows. (-X, +X, -Y, or +Y); the Slew Enable switch must first be depressed.

•

Slew Enable — Allows movement of the cutter head and beam; depress and hold before using joystick.

•

Servo Power Enable — Turns on power to the servo motors.

•

Stop — Stops the current operation of the cutter.

GTxL GERBERcutter System

•

Vacuum — Turns cutting table vacuum on or off.

•

KI Null — N/A

•

Fabric Alignment — Sets fabric alignment when pressed twice.

•

Manual Bite — See EStop and CTOT Control Panel section

•

Initialize — Moves the cutter head to the home X0,Y0 position on the table.

•

Trim Cut — Manually trims the edges of a spread.

•

Origin — Sets the current position of the origin light as the origin of  your marker. Marker origin is the X,Y coordinate where the marker  starts.

•

Start — Starts the cutting on the GERBERcutter.

•

Sharpen Knife — Manually sharpens the knife blade one cycle.

•

Status Light — Indicates changes in status, or mode, for the cutter. The light flashes when the cutter is in Manual Bite or Trim Cut mode or  when a controller error occurs.

Feed Rate Control Feed rate for the cutter is controlled by a slider located on the C-200MT Main Cutter Control screen. See Feed Rate Slider section in C-200MT Software for  GTxL chapter.

GTxL GERBERcutter System 15 

Operator Console You use the operator console and the beam control panel to run the GERBERcutter. The operator console includes the front end processor (FEP) or  PC. Depending on the GERBERcutter model, the console may be a freestanding or attached pedestal or may be a PC system mounted directly to the side of the cutter. Monitor 

 Auxiliary Joystick for AccuMatch option

Pointing Device EStop CTOT Auto Enable Manual Bite Keyboard Stop

PC with disk drives

Typical Components

16

•

Monitor — Receives computer video signals from the PC and displays information on the screen.

•

Keyboard — Device with keys, like those on a typewriter, that lets you enter data and communicate with the C-200MT program.

•

Function keys — Each key across the top of the keyboard performs a C-200MT command to operate the cutter. Refer to the chart at the end of  this Getting Started manual.

•

Pointing device — Moves the cursor around the screen to select cut files, setups, or pieces and enter menu commands and information in dialog  boxes. Your pointing device may differ from the one shown.

GTxL GERBERcutter System

•

•

Servo power enable — This control turns on power to the servo motors, that move the cutter head and beam as the GERBERcutter cuts material. PC — Computer with hard disk drive, 3.5 inch disk drive, and CD disc drive.

EStop and CTOT Control Panels There are two control panels at the take-off end of the cutter, one on each side. Controls in this panel allow you to control the CTOT for removal of cut pieces.

Stop

CTOT Jog

CTOT Auto Enable

EStop

CTOT Auto Enable Turn this switch to OFF in order to prevent the CTOT from moving during either an automatic or manual bite. This is useful whenever there is a delay in removing cut pieces. Depending on the GERBERcutter, this control may be located on the operator console or table. When turned to ON, the CTOT automatically moves cut pieces from the table surface while a bite is being cut.

CTOT Jog Use this switch to perform a manual convey. The switch is marked by the following icon:

GTxL GERBERcutter System 17

EStop Switches and Plungers Emergency Stop Emergency Stop (EStop) is a safety feature. You must know how to use EStops  before operating the GERBERcutter. An EStop halts all table motion in case of  danger to people, the GERBERcutter, or the material being cut. Pressing an EStop switch or EStop plunger immediately shuts off all power to the conveyor, vacuum generator, cutter head, and beam. All motion stops. Only the operator console stays on. You must perform a recovery procedure before you can use the GERBERcutter again.

EStop Plungers EStop plungers (sometimes called paddles) are large yellow buttons strategically located on the beam. They depress automatically whenever interference is encountered, such as someone leaning against the table when the beam is moving in that direction.

EStop Switches EStop switches are large red buttons that have a yellow ring on the surface just  behind the button. An EStop switch is located on or near to the operator console and on the beam control panel. Additional button locations depend on the GERBERcutter model. To stop the system:

Press one of the red EStop switches. All table motion stops. 1. For error recovery procedures, refer to the Recovery chapter. For error  messages, refer to the C-200MT Software User’s Guide or online help.

CAUTION:

18

GTxL GERBERcutter System

Do not move the spread or jog the conveyor after an EStop. If you do, it will be very difficult for the cutter to start cutting in the right place.

EStop Locations — GTXL

Material Advance Controls Material advance controls are used to jog, or move, material from a spreading table onto the conveyor and along the cutting table. One or two button controls allow you to select a mode (forward or reverse) and jog while in that mode. These controls are located on the operator side of the cutter. The exact number  and location of these control(s) depends on the model of your GERBERcutter. Note:

If the GERBERcutter has the lateral drive option, the pendant with lateral drive controls is attached to this panel.

GTxL GERBERcutter System 19

Material Advance Controls — GTxL A single jog control switch allows you to manually select forward or reverse mode and jog the conveyor accordingly. This switch is located at the take-off  end of the cutter. An EStop switch is located on the same panel.

Forward

Jog Button

Reverse

To jog material onto the cutting surface: 1. Turn the jog switch to the left and hold. 2. Release switch when done.

3. To reverse material: 4. Turn the jog switch to the right and hold. Jog Switch

5. Release switch when done.

Presser Foot Adjust This control adjusts air pressure for the presser foot on the cutter head. You must set the air pressure for the type of material and thickness of lay being cut. Depending on the GERBERcutter, this control may be located on the head,  beam, roll bar or table. On some GERBERcutter systems, it is identified with the following icon:

Air Pressure Gauge This gauge shows current presser foot air pressure. Depending on the GERBERcutter, this may be located at the operator console or on the head,  beam, roll bar, or table.

20

GTxL GERBERcutter System

Lateral Drive Controls If your GERBERcutter has the lateral drive option, controls are provided on the operator side of the cutter which control movement of the cutter   between spreading tables. The exact location of these controls and whether  they are located on a panel or a pendant, depends on the model of your  GERBERcutter. The cutter moves on platform wheels that ride along rails in the cutting room floor.

Typical Controls •

Forward — Moves the table forward laterally to align it with a spreading table or take-off table.

•

Reverse — Reverses table movement laterally for alignment purposes.

•

Brake — ON sets the brakes, locking the cutter in position; OFF releases the brakes.

Lateral Drive Controls — GTxL If the GERBERcutter has the lateral drive option, the pendant with the lateral drive controls is attached to the material advance panel located at the take-on end of the cutter.

Options for GERBERcutter Systems Gerber provides options to enhance the performance of your GERBERcutter. Here is a list of hardware and software available. For more information, call your  local Gerber Sales and Service office. •

Lateral Drive

•

Right Side Option (RSO)

•

CTOT

•

Barcode Reader 

•

Drill

•

Bristle Cleaner 

•

Resealer 

•

Power Processor 

•

AccuMatch

GTxL GERBERcutter System 21

Lateral Drive Option A lateral drive option is available for most GERBERcutter systems. This option allows one cutter to move from spreading table to spreading table. Included in the option are: •

Platform wheels which ride in tracks in the cutting room floor 

•

Lateral drive controls

•

Vacuum exhaust stack on mast

•

Mast and overhead trolley to carry electric cabling

Right Side Option The Right Side Option (RSO) allows you run the GERBERcutter from the right side of the cutting table. This lets you spread material with its straight edge on the right side, which is more practical for some applications. On a right-side option GERBERcutter, the operator console and beam control panel are located on the right side of the cutting table as seen from the take-on end. An RSO option is available for all GERBERcutter systems. GTxL GERBERcutter systems can be reconfigured on-site for an RSO option.

Conveyorized Take-off Table (CTOT) Depending on the GERBERcutter model, a CTOT is built into the cutter or  available as a moveable unit. Cut pieces and scrap material moves off of the cutting table onto the CTOT. If the CTOT is placed in front of another table,  pieces can continue to move onto that table for picking and bundling. Otherwise, cut pieces are picked up directly from the CTOT and scrap material can drop away into a bin or onto the floor.

Resealer Option The resealer uses plastic film to automatically cover, or seal, the cut area of the lay. Covering areas on the table where pieces have already been cut, improves cut quality for remaining pieces by maintaining vacuum. Resealers on higher ply GERBERcutter systems have a bar that can be raised to allow uncompressed  pieces and material to be conveyed off of the table.

22

GTxL GERBERcutter System

POWER Processor  The POWER Processor ™ lets you change cut files so that the GERBERcutter  works more efficiently. Input to the POWER Processor is a cut file produced on a marking and grading system such as Gerber’s AccuMark or MicroMark. Output is a modified cut file. Altering a cut file can improve cut quality, cut speed, material use, and cut file efficiency. The POWER Processor lets you: •

Change piece cutting sequence

•

Change the start point of a piece

•

Add or remove knife lift and plunge points

•

Add or remove Opstop points for plaid/stripe matching

AccuMatch With the Gerber AccuMatch system, you can check match points and make any necessary adjustments with accuracy and speed. A color video CCD module, or  digital camera, captures images of the spread at all matching positions (Opstops) in a cut file and displays on-screen an image of the material at this location. You can accept the match point as shown or reposition a cross hair cursor relative to the fabric design. The AccuMatch system option includes the following:

Hardware •

Camera with adjustable lens

•

Light

•

Mounting fixture

•

Camera head cover 

•

Cables

•

High performance video board

•

Auxiliary slew control (joystick) at operator console

Software Check with your Gerber Sales representative for availability and/or the appropriate AccuMatch and C-200MT software versions for your cutter.

GTxL GERBERcutter System 23

Drill Options All GERBERcutter systems support a drill option. The following options are available, depending on the cutter model. Gerber also provides drill bits in a wide variety of sizes and types.

Drill Options — Electric Cutter GTxL

Drill 1

Drill 2

Electric

Electric

Bristle Cleaner Options Removing lint and debris from the table surface promotes vacuum flow through the BRISTLE SQUARES. Options available for cleaning the work surface depend on the GERBERcutter model. •

Detachable vacuum hose

•

Automatic Bristle Cleaner 

Bristle Cleaning — Manual Vacuum A vacuum hose can be connected to the vacuum system and used, as required, to manually clean the work surface. Depending on the GERBERcutter, an optional Automatic Bristle Cleaner is available.

Bar Code Reader  This option, available for all GERBERcutter systems, allows you to use a bar  code reader to open individual cut files or job queues. The Bar Code Reader is capable of scanning cut file names 20 characters in length. This was tested using Code 39 bar codes. When this feature is turned on, all bar codes read (except setup files *.CNF) are assumed to be queues and are automatically opened for running. If this feature is turned off, each bar code read will be opened as single cut file.

24

GTxL GERBERcutter System

C-200MT Software for GTxL  The C-200MT software is designed to operate on various GERBERcutters in various work environments. C-200MT performs interface and cutter control functions on all new GERBERcutters.

Multitasking The C-200MT program version 1.7 or greater runs in Windows NT 4. You may already be familiar with Windows. If not, refer to the Windows NT Quick   Reference Guide. Your company will appreciate the fact that Windows NT allows multitasking. This means additional tasks can be performed while a marker is being cut. These tasks can include: •

Viewing a different cut file/marker 

•

Creating a job queue

•

View system setups

•

Using File Manager 

•

Generating reports

Software Installation The C-200MT software performs user interface and cutter control function on the GTxL GERBERcutter. Windows NT 4.0 must be installed on your PC in order to run C-200MT software. C-200MT software is installed on a new cutter at the factory. As new releases  become available, you may choose to update C-200MT software in order to utilize new features. Follow instructions on the inside front cover of the software CD. If Windows NT software has to be reinstalled, contact your Field Service representative before installing Windows NT and C-200MT software on your  GERBERcutter.

Accessing C-200MT Program To start up the C-200MT program

1. Turn on the main power circuit breaker for the cutter. See GTxL GERBERcutter System chapter. 2. Press Enter to select Windows NT Workstation.

C-200MT Software for GTxL

25 

3. When prompted, press Ctrl + Alt + Delete to log on. 4. When prompted for a password, type your password and then press Enter or click OK  to display the Main Cutter Control screen.

Note:

The system is shipped from the factory without an NT  password. Press Enter to continue.

5. Double-click the C-200MT icon on the Windows desktop. C-200MT Main Cutter Control Screen

When you turn on your GERBERcutter, the following screen displays. Features in this screen are explained in the following sections. For information on how to use these features, refer to C-200MT online help or to the C-200MT Software User’s Guide.

Right click for Settings options

Menu Bar 

Feed Rate Slider 

Tool Bar 

Cut File Info Button

Gauges 2 Line Output Display Queue Info Button

Right click for  File Display options

File Display  Area

Status Bar 

Menu Bar 

The menu bar has drop-down menus that allow access to the interface and cutter  control functions in the C-200MT program. Each menu choice is called a command. The following table lists the menus available in the Main Cutter  Control screen.

26

C-200MT Software for GTxL

System Setup Button

Tool Bar  The tool bar provides an additional way to perform frequently-used tasks for  operating the cutter. Click on an icon with the pointing device to select. Hold the cursor over a tool bar icon to view its name and corresponding function key that you can press on the keyboard, if preferred. Icons in the tool bar are explained in a chart at the end of this manual.

Settings Options To access Settings Options (explained below), right click anywhere in the gray  bar area, except on a gauge or other button. To turn an option on, click that option. A button is created and displays as long as an option is active. To turn an option off, click on the button displayed for that option. Option

Use To

Turn On Dry Run

Check the cut file/marker by processing without cutting.

Enable Single Stepping

Process cut data one block at a time.

Enable Continuous Run

Reprocess an open cut file/marker until you manually stop the process.

Setup Data Scaling

Change scaling to adjust the size of a cut file/marker to the size of the available material.

Setup a Fabric  Alignment Angle

Set a different angle before cutting a cut file/marker.

Setup a Clipping Window

Prevent the knife from cutting outside of one or more edges of the spread.

Gauges Status gauges appear on-screen as soon as servo power is enabled, replacing the Enable Servo Power prompt. These gauges are frequently-updated indicators. The Percent Complete, although not among the group of gauges described above, indicates cut file/marker completion.

Vacuum Level Gauge Shows current vacuum level in inches or centimeters per mercury. Click the gauge button to access the Vacuum Settings dialog box. When the level is too low the bar graph turns red. Also, the Vacuum Low Caution  message displays when the vacuum is too low for processing the current cut file/marker.

Knife Speed Gauge Shows current knife reciprocating speed in revolutions per minute (rpm). Click  the gauge button to access the Knife Speeds dialog box.

C-200MT Software for GTxL

27 

Cut Speed Gauge Shows current cutting speed in inches or centimeters per minute for the cutting head. The Cut Speed gauge indicates the slowdown by a decrease in the width of  the green bar indicator. Click the gauge button to access the Cut Speed dialog box.

Knife Wear Gauge Shows the number of sharpens that have occurred since the last knife; it also indicates how many sharpens remain before the knife needs to be changed. When the maximum number of sharpens has been reached, the bar graph turns red and the Knife Life Exceeded prompt displays. Click the Knife Wear gauge button to access the Knife Wear and Sharpening dialog box.

Feed Rate Slider  On a GTxL GERBERcutter, this slider allows you to view and change the feed rate at which the cutter head and beam move across the table. The range is from 0% (minimum) to 100% (maximum); 0 indicates no movement.

Percent Complete Gauge This gauge displays at the bottom of the File Display area. It shows the  percentage of cutting completed so far for the current marker; the percentage is  based on distance cut relative to total cut distance as calculated during  preprocessing.

Two Line Output Display This display relays informational messages that do not require any user  acknowledgement. You can scroll through the messages using the scroll buttons on the window. These can include: Initializing... Command Executed Move Complete

28

C-200MT Software for GTxL

Cut File Information Button This button displays the cut file/marker name when one is open. Click the button to display the Cut File Information dialog box. This dialog box shows the cut file name and path as well as the length, width, number of bites, and number of   pieces in the open cut file. The dialog box also allows you to open/close a cut file/marker or re-run a file. Information concerning the current cut file and cut job displays in this window. This can include: •

 Name of setup used

•

Cut path (drive and directory)

•

Marker (cut file) name

•

Length and width of marker 

•

Bite number currently being processed

•

Piece number currently being processed

•

Origin in X and Y

•

Job queue, if any

•

Cutter status mode (determines which commands can be used currently)

System Setup Button This button displays the system setup dialog box. From here, you can load a new setup or save a setup you created. Refer to C-200MT online help

Queue Information Button This button displays the Queue name when one is open. Click the button to display the Queue Information dialog box. This dialog box allows you to: •

Check the current job, if any

•

Open a queue

•

Close the current queue

•

Select the next job in the current queue

•

Open Queue Manager to edit the current or create a new queue. Refer to C-200MT online help.

C-200MT Software for GTxL

29

File Display Area When a cut file/marker is opened, this screen shows the current bite and indicates the piece currently being cut. The status of this window is updated several times a second. Information concerning the current file and job displays in this window. This can include: •

Piece number currently being processed

•

Cutter status mode

•

Origin in X and Y

•

Bite number currently being processed

•

Job queue, if any

•

Length and width of marker 

File Display Options To access File Display Options (explained below), right click in the File Display area. Right clicking provides access to the following options, depending on whether a cut file/marker is open or not: Option

Use To

View

Access the CutView utility. Refer to C-200MT online help.

Close

Close currently displayed cut file/marker.

 About

Rerun

Display the Cut File Information dialog box. This dialog box shows the cut file name and path as well as the l ength, width, number of bites, and number of pieces in the open cut file/marker. The dialog box also allows you to open/close a file or re-run a file. Reopen and display the last cut fi le/marker opened. The system will display the file’s name in the menu. Note: If you attempt to rerun a currently displayed cut file/marker, the system will prompt you to close and reopen that file.

Open a Different Cutfile

Open a different cut file/marker than the one currently open.

Piece Colors in File Display Area Pieces change color during and after cutting in order to differentiate pieces that have not yet been cut. Pieces are first white. When a piece is about to be cut, it turns light blue. As the knife cuts a piece, the cut line becomes yellow. After  each piece is cut, its piece number turns yellow, too.

Status Bar  When a menu command is highlighted, a brief description about the command displays in the Status bar.

30

C-200MT Software for GTxL

Basic Concepts  Direction and Location Gerber uses specific terms to describe direction and location on the cutting table. Learning these words will make it easier for you to find your way around the GERBERcutter.

Ends and Sides Each side of the cutting table is named so you can identify it easily. The take-on end is where material comes onto the work surface for cutting. The take-off end is where material leaves the work surface after cutting. The right and left sides are as they would appear to someone standing at the take-on end.

Right Side (Far Side)

Take-on End

Take-off End

Left Side

Beam Control Panel

Basic Concepts 31

X, Y, and C-axes The GERBERcutter uses three imaginary lines or axes to tell direction and location on the cutting table. They are the X, Y, and C-axes, as shown below.

Y-AXIS

C-AXIS

X-AXIS

If you stand at the operator console, the Y-axis runs across the table, the X-axis goes from left to right, and the C-axis is in the cutter head. The beam moves along the X-axis, the cutter head travels the Y-axis, and the knife turns around the C-axis in the cutter head. Movement is always in a plus (+) or minus (-) direction on the X and Y-axes. If you stand at the operator console:

+X is to your right. +Y is away from you. -X is to your left. -Y is toward you.

+Y

-Y

-X

32  Basic Concepts

+X

Location  is also given in terms of the X and Y-axes, as shown below.

If you stand at the operator console, the point X0, Y0 is at the lower left corner  of the work surface, as shown below.

X0, Y0

All locations on the work surface are relative to this position. Unlike direction, location is always stated in positive numbers. To find the point (X=24 in., Y=36 in.), start at X0, Y0. Measure 24 in. to the right along the X-axis. From there, measure 36 in. away from you on the Y-axis . You are now at the point X24, Y36.

Origin Just as the table has a X0, Y0 position marking its lower left corner, so does each cut file/marker. The X0, Y0 position of the cut file/marker is called the origin. All data points (locations) of the cut file/marker are relative to the origin. Before the GERBERcutter can cut a cut file/marker, you must set the location of  the origin. The cutter then cuts each piece relative to this point. The origin is set from the beam control panel or at the operator console (see chapter 3). The origin light is a red laser light located in the cutter head that shines on the cutting table (see the Safety chapter of this manual).

WARNING!

The origin light uses a Class IIIa laser. Do not look directly into the laser beam without protective glasses. Do not place any reflective (shiny) material on the cutting table. Remove watches, rings, and other   jewelry. Reflected laser light may cause eye injury.

Basic Concepts 33

The origin must be close enough to the lower left corner of the table so that the cut file/marker can fit on the table. For example, the origin shown below is at X25, Y50.

With that origin, the cut file/marker extends off the table in the Y direction. You can correct this situation by moving the origin to X25, Y25.

If the cutter cannot cut the cut file/marker because it will go off the table, you will receive an off table message, such as one of the following: Off table in +Y Off table in -X

34 Basic Concepts

Using the Check Origin feature, the system automatically verifies that the cut file/marker will fit on the cutting table with the current origin. It does this before cutting the cut file/marker. If the origin will not work for your file, the system displays an error message like this: Bad Origin: X too high (x.xxx) acceptable range: x.xxx - x.xxx

where x.xxx is a table location in the X direction. You get a similar message if the origin needs to be corrected in the Y direction.

Bite Feeding GTxL systems use a conveyor for bite feeding. Bite feeding is a feature that matches cutter head movement with conveyor movement, permitting automatic cutting of a long spread. The GERBERcutter does this by cutting the spread in sections. The marking system sets the length of each section in inches or  centimeters as one bite. After the cutter pulls the bite onto the cutting table and cuts it, the conveyor automatically advances, positioning the next bite on the cutting surface. An example of how the conveyor and bite feeding work is shown on the next  page. Diagram 1 shows a 48.8 m (160 ft.) spread of material that the marker maker  has divided into 20 bites, each 2.4 m (8 ft.).

To begin automatic cutting, the conveyor pulls the leading edge of the spread onto the cutting surface with the aid of underlay paper. The conveyor moves until it pulls the first bite onto the cutting table as shown in Diagram 2. The GERBERcutter cuts the first bite, including pieces that extend into the second bite As shown in Diagram 3. The knife cuts a slit in the selvage of the material to mark the origin of the second bite. The slit (or edge clip) made by the marking system is a reference point in case you stop cutting during the second  bite.

Basic Concepts 35 

 Next, the conveyor automatically moves the first bite down the cutting table and  brings the second bite in position to be cut as shown in Diagram 4. While the  bundle handlers are removing the pieces from the first bite, the GERBERcutter   begins cutting the second bite. After the system completes the second bite, the conveyor moves the third bite onto the cutting surface. It brings the second bite down to the bundle handlers, and moves the first bite scrap from the cutting surface to the take-off table, where you can collect or discard it as shown in Diagram 5. The GERBERcutter keeps feeding bite after bite until it cuts the whole spread.

36  Basic Concepts

Basic Cutting  Sections in this chapter explain: •

Spreading material.

•

Turning the GERBERcutter on and off 

•

Basic cutting on your GERBERcutter 

For additional information on how to use C-200MT program features, refer to the C-200MT Software User’s Guide.

Spreading Material CAUTION:

Different materials require specific spreading methods for the best cutting results. Also, spreading requirements are different for  systems without a conveyorized table. The following procedures are general guidelines only.

To spread material on the spreading table

1. Place an underlay of perforated or air-porous paper (25 to 60 lbs.) on the spreading table. Be sure the paper is straight on the table and extends at least 0.3 m (1 ft.) beyond the leading edge of the spread. The underlay lets you move the spread without pulling or disturbing the material. When vacuum is applied, the underlay keeps the material clean and in place. It also provides extra support for stretchy and lightweight material. 2. Using the method appropriate for your site, spread the material on top of the perforated paper. Normally the straight edge is on the operator’s side of the cutting table.

CAUTION:

Do not exceed your GERBERcutter’s maximum compressed material ply height (see the System Description in documentation for your cutter). Exceeding the maximum material ply height will lower  cut quality, shorten knife life, and may damage your  GERBERcutter.

3. If you use full–size plots to identify individual pieces after they are cut,  put the correct one on top of the spread.

Basic Cutting

37 

Basic Cutting The following sections explain how to use C-200MT features to perform basic cutting procedures. At Cutter 

At Operator  Console

1. Turn on cutter  2. Enable servo power 

3. Initialize cutter 

4. Position first bite of spread on table 5. Select setup

6. Open cut file/ marker 

7. Turn on vacuum 8. Position laser light

9.Set marker origin

10. Select cutting speed or feed rate

11. Turn on knife motor  12. Start processing cut file/marker 

Note:

38 Basic Cutting 

Read the safety precautions at the beginning of this manual  before performing any operation at the cutter.

Turning on the Cutter  Depending on your GERBERcutter, circuit breaker(s) and/or a switch located outside of the vacuum and electric enclosure(s) allow you to turn power ON or  OFF for the FEP (or PC), vacuum system, C-200 cutter controller, servo motors, and conveyor. Enclosure(s) may be located at the side or at the end of the cutter  or on a separate table along side of the cutter. To turn on the main power circuit breaker for your cutter, see the Safety Procedures chapter in this manual.

Enabling Servo Power  Pressing the Servo Power Enable switch turns on power to the servo motors. These motors move the cutter head and beam during cut processing.

To enable servo power 

1. Make sure that cutter power is turned on and the C-200MT program is running. 2. When prompted, press the Servo Power Enable switch. Depending on your GERBERcutter, this switch may be located at the operator console or at the beam control panel. The servo motors are turned on and gauges display across the top of the Main Cutter Control screen.

Basic Cutting

39

Initializing the Cutter  Use the Initialize feature to identify the zero position for the table in X and Y. This is also called the home position and is written as (0,0). Limit switches tell the C-200MT when the cutter head reaches the (0, 0) position. For information about basic cutter concepts, see that chapter in this manual.

Note:

You must initialize the cutter before processing markers. Otherwise, an error message displays.

To initialize the cutter 

1. Make sure that the cutter power is turned on, the C-200MT program is running, and the servo power is enabled. 2. Do one of the following: −

Press the Initialize switch on the beam control panel. Press the Initialize key on the keyboard.

−

−

From the Cutter menu, select Initialize .

−

Click the Initialize button on the tool bar.

The cutter head and beam moves to the (0,0) position on the table and the origin is reported in the System Messages box.

Note:

If the cutter is set up for the Right Side Option, the cutter  head and beam moves to the right side of the table.

Positioning the First Bite After the cutter is initialized, use the jog switch at the take-on end of the cutter to advance the spread (material) into cutting position on the table. This will be the first bite. Then cover the spread with plastic film. For specific information on spreading a marker and positioning the first bite, see the first page in this chapter.

40 Basic Cutting 

Selecting a Setup A setup is a file containing parameters that enable or disable various features, options, and modes depending on such considerations as ply height, material characteristics, or marker width. Use the Setup List page to select a new Setup from the list of all Current Setups available. To select a setup

1. Do one of the following: −

Press the Settings key on the keyboard.

−

Click the Settings button on the Cutter Main Control screen.

−

Click the Settings button in the tool bar.

−

From the Setup menu, select Settings.

2. If some other page is selected in the System Setup dialog box, click the Setup List tab. 3. Use the pointing device to select the Name of the setup you want. 4. To select this setup as the current setup, click the Apply or the OK   button. Apply loads the new setup and leaves the screen open; OK  loads the new setup and closes the screen. Selecting another setup page is the same as clicking Apply. 5. When prompted to Activate Selected Setup, check your changes and then click the Yes button. 6. When satisfied with the changes, press Enter or click the OK  button.

Basic Cutting

41

Opening a Cut File/Marker  Use the Marker Open feature to select marker or cut file and open it for   processing. You can enter a cut file/marker name directly or choose from a list of  available files. You also can search for piece names using the “*” and “?” wildcards. For example, to find files with names similar to SUIT123, SUIT456, and SUITABC, type SUIT*.

Default Directories/Storage Areas  For cut data files the default directory is C:\USER. For AccuMark markers or  cut data, when you first open this dialog box after starting the C-200MT  program, the first storage area on the C: drive is selected by default. After you make a selection and until you shut down C-200MT, the default storage area for  AccuMark markers or cut files will be the last storage area from which you selected AccuMark data. To open a marker 

1. Do one of the following: Press the Open Marker key on the keyboard.

−

−

From the Marker menu, select Open.

−

Click the Open Marker button on the tool bar.

The Marker Open screen displays.

Note:

If Marker Size: Use Auto Calculate is turned OFF and certain features, such as Right Side Option, are turned ON, you will  be prompted to enter a new marker width. Press Enter to accept the marker width or type a new marker width and then  press Enter.

2. To change drives and directories or storage areas, you can use the  pointing device, Tab key, or arrow keys to make your selections. 3. To select the Type of File you want to open, click on the button marked with an arrow to the right of that field. Choices are: −

AccuMark cut

−

AccuMark marker 

−

All (other cut) files

4. Select the cut file/marker you want to process.

42 Basic Cutting 

5. If you selected an AccuMark marker, you may be prompted to change cutter and notch parameter tables. See the next sections. 6. Press Enter or click the OK  button to return to the Main Cutter Control screen. 7. The first bite of the selected cut file/marker is processed and displays in the File Display area. Verify that this is the marker you want to cut.

Changing AccuMark Parameter Tables To make changes to the Cutter and Notch parameter tables that are associated with the marker file currently being opened, one or both parameters in the Security category must be enabled.

Note:

Supervisors can change the access level of these parameters using the Advanced button in the Parameter Manager.

To select different parameter table(s)

1. Make sure the User Parameter Table Selecting parameter is enabled. 2. Open an AccuMark marker. The AccuMark Parameter Table Selection dialog box displays with the name of the current marker displayed.

Note:

Edit buttons are not available unless the User Parameter  Table Editing parameter is also enabled.

3. To check parameter tables that are being used by another marker or  to select a different marker, click the Select button for that item. 4. To select a different Cutter parameter table, click the Select button for  that item. The name of the new table displays. 5. To select a different Notch parameter table, click the Select button for  that item. The name of the new table displays. If you decide to use the internal Notch parameter table instead, click the Internal button. 6. Press Enter or click OK . The marker opens in the Cut File display area.

Basic Cutting

43

To edit parameter table(s)

1. Make sure the User Parameter Table Editing parameter is enabled. 2. Open an AccuMark marker. The AccuMark Parameter Table Selection dialog box displays with the name of the current marker displayed. Note: Select buttons are not available unless the User Parameter Table Selecting parameter is also enabled.

3. To edit the Cutter parameter table: a) Click the Edit button for that item.  b) When prompted that changes you are about to make will overwrite the parameter table file, click OK. The Cutter Parameter Table Editor displays. c) Make desired changes and press Enter or click OK. 4. To edit the Notch parameter table: a) Click the Edit button for that item.  b) When prompted that changes you are about to make will overwrite the parameter table file, click OK. The Notch Parameter Table Editor displays. c) Select the Notch type you want to make changes for. d) Enter values for Perimeter Width, Inside Width, and/or Notch Depth. e) Select and edit each Notch type you want to change, and then press Enter or click OK. 5. Press Enter or click OK . The AccuMark marker opens in the Cut File display area.

44 Basic Cutting 

Cutter Parameter Table Editor  Fields in this editor correspond to fields in the AccuMark Cutter Parameter  Table.

Note:

Field

To specify the Notch Parameter Table, use the AccuMark Parameter  Table Selection dialog box.

Description

Cutter Type

The cutter type does not automatically change the default values of the table. STATIC is a type of GERBERcutter that has a fixed cutting surface equal to the table length. CONVEYOR TABLE is a type of GERBERcutter that has a continuous  belt for the cutting surface. As the spread is fed on from one side, the cut  pieces come off the other. TRAVELLING CONVEYOR is a GERBERcutter that moves from one spreading table to the next on floor rails.

Table Length

Usable table length.

Table Width

Usable table width.

X Scale

Determines the scale of the cut data in Y direction on the table.

Y Scale

Determines the scale of the cut data in X direction on the table.

Perimeter  Tool

Choices are: KNIFE to cut the marker  PEN to plot the marker if the cutter is equipped with a pen BLANK the perimeter will not be cut or plotted

First Bundle Code

The default bundle code is A and can be edited with numeric or  alphanumeric values.

Edge Tolerance

Used for tubular goods. If the piece perimeter is placed within the given tolerance, the cutter will dry haul for the fold. The pattern dimensions are increased to the defined value.

Maximum Move

This safety feature controls the cutting head on long straight lines. Data  points are added during cut process if a straight segment is over the indicated value.

Fold Overcut

Used for tubular goods. The cutter will cut the defined amount past the edge of the marker on folded pieces. This is to make sure the piece is fully cut. The folded pieces must have the piece option F assigned.

Cut Small Slow

Used to ensure good quality on small pieces by cutting them at the indicated percent of full speed (increments of 5 with a minimum of  60%). This prevents pushing; refer to the Applications manual for your  cutter.

Basic Cutting

45 

Field

Description

Bite Clip Amount

The length of a cut made in the selvage of the goods. Used to reorigin the cutter head at the beginning of a bite for a conveyor. See Bite Parameters.

Park in Bite

When cutting lofty goods, the cutting head needs to be moved to the edge of the table when the GERBERcutter advances. Otherwise, when the vacuum releases, the goods are no longer condensed and could be damaged. This is calculated based on 0.00 as the origin. To move the head to the far side of the fabric, enter the width plus an additional amount to ensure the head moves off entirely. See Bite Parameters.

Bite Length

Indicates a specific bite length for the available cutting surface. See Bite Parameters.

Bi-L/R Cut

NO means the option will not be activated YES indicates lefts will be cut in opposite direction from rights.

Bi-L/R Mirr  Cut

 NO indicates mirrored pieces will be cut in clockwise direction YES indicates one half of mirrored piece will be cut in opposite direction from the other half on a common perimeter point of the mirror line. The cutter will dry haul back to the center back hem and resume cutting in the counter clockwise direction, finishing at the center.

Cut Small Pieces First

 NO means the option will not be activated YES indicates the pieces not identified as major pieces in AccuMark will  be cut first.

AutoMatch

YES indicates the cutter has AutoMatch option.

Cut Net Parts

YES cuts pieces in a defined block for blockfusing.  NO cuts the block.

Variable Biting

Indicates that bite lengths change according to the size and location of   pieces in the marker. Choices are: Yes, for a conveyor table so the system calculates the bite according to the length of the cutting table and the pieces.  No, for a conveyor table when you determine and enter the fixed bite length at the cutter.  No, for a static cutter.

Labeller

Check to use a labeller.

Label Width

Usually 1.25 inches; the labeller can override these values

Label Height

Usually 2 inches; the labeller can override these values

Label Margin

Usually .25; the labeller can override these values

Label/Tool

These two drop-down list boxes establish what tool the GERBERcutter  uses for specific internal labels. Possible tools are KNIFE, PEN, DRILL1, DRILL2, OPSTOP, LABELLER, and blank. A blank field allows an internal label to be turned off. The default labels are: C Opstop;D Drill1;I Knife

46 Basic Cutting 

Using Rerun Use the Marker Rerun feature to reopen the previously selected cut file/marker. To rerun the last cut file/marker 

1. From the Marker menu, select Rerun. The cut file/marker opened  previously displays in the File Display area.

Turning on the Vacuum Use the Vacuum feature to turn table vacuum ON in order to process markers. When finished cutting, you can repeat the following procedure to turn OFF table vacuum. Vacuum System parameters that control the vacuum system are set using the Parameter Manager. To turn the vacuum on in order to cut

1. Make sure that the first bite is positioned on the table and the correct cut file/marker is open. 2. Do one of the following: −

−

Press the Vacuum On/Off switch on the beam control panel. Press the Vacuum key on the keyboard.

−

From the Cutter menu, select Vacuum.

−

Click the Vacuum button on the tool bar.

Basic Cutting

47 

Positioning the Laser Light The laser origin light is located on the cutting head. Refer to the GERBERcutter’s operator manual or Getting Started for the location of the switch for this light.

WARNING!

The origin light uses a Class IIIa laser product. To avoid injury to your eyes, do not look at the laser at any time. Also, do not place any reflective material, such as mirrors, polished steel, or jewelry on the cutting table.

At the beam control panel, press the Slew Enable and Arrow switches to position the laser origin light at the corner of the spread closest to the X0,Y0 values on the cutting table.

Setting the Marker Origin Use the Origin feature to establish the origin for a marker. To set the marker origin

1. After positioning the laser light at the corner of the spread as explained above, do one of the following: −

−

Press the Origin button on the beam control panel. Press the Origin key on the keyboard.

−

From the Cutter menu, select Origin.

−

Click the Origin button on the tool bar.

The origin is reported in the System Messages box, where x.xxx and y.yyy are the absolute table coordinates (origin) for the lower left corner of the marker.

48 Basic Cutting 

Selecting Cutting Speed Select the appropriate cutting speed for processing the open cut file/marker. Depending on your GERBERcutter, use the Cutting Speed dial at the beam control panel or the Feedrate slider on the C-200MT Main Control screen. Refer  to the GERBERcutter Applications manual for recommended settings for cutting speed.

Turning on the Knife Motor  At the beam control panel, turn on the knife motor.

WARNING!

The knife blade is very sharp. Use extreme caution when working near the knife blade.

Processing a Cut File/Marker  Use the Start feature to begin processing, or cutting, a cut file/marker. To start processing a cut file/marker:

1. Make sure you have completed all of the previous procedures in this chapter. 2. Do one of the following: −

−

Press the Start switch on the beam control panel. Press the Start key on the keyboard.

−

From the Cutter menu, select Start.

−

Click the Start button on the tool bar.

The piece being cut is outlined in the File Display are and the current  piece and bite number display in the System Status window. 3. When prompted that processing is complete, press Enter or click OK .

Basic Cutting

49

Trim Cut Use the Trim Cut feature to cut across a spread in order to trim away excess material and plastic. To use Trim Cut

1. Do one of the following: −

Press the Trim Cut switch (marked by scissors) on the beam control panel

−

From the Cutter menu, select Trim Cut.

At the beam control panel, the Error Warning Light starts flashing to indicate you are in Trim Cut mode. 2. Immediately, press and hold the Slew Enable button while using the  joystick or pressing slew keys to make required cut(s). 3. To exit Trim Cut mode, do one of the following: −

At the beam control panel, press the Stop switch or wait until the Error Warning Light stops flashing.

−

At the operator console, press Esc.

Note:

To position and lower the knife before using the Null KI command for GERBERcutters that support Knife Intelligence, turn the feed rate to zero and then follow the steps above.

4. To exit Trim Cut mode, do one of the following:

50 Basic Cutting 

−

At the beam control panel, press the Stop button.

−

At the operator workstation, press Esc.

Exiting the Program This section gives the steps necessary to close the C-200MT program and shut down the cutter.

CAUTION:

To avoid losing data, always quit the C-200MT program  before shutting down Windows NT. Also, shutdown Windows NT before turning off the main circuit breaker  for the cutter.

To quit the C-200MT program

1. Make sure that the cutter is idle (not processing data). 2. From the Quit menu, select Confirm. To shut down the cutter 

1. Click on the Start button in the Task bar. Do one of the following: −

Select Shutdown.

−

Press ALT + F4.

2. In the Shutdown dialog box, click the radio button next to Shutdown the Computer. Then press Enter or click the OK  button. 3. When prompted that it is safe to turn off your computer, turn off the main power circuit breaker.

Basic Cutting

51

52 Basic Cutting 

Recovery  Recovery procedures allow the cutter to resume cutting after a power loss, EStop, or a system power down interrupts cut processing. An EStop occurs whenever cutter motion is stopped by pressing one of the emergency stop (EStop) switches or plungers located on the cutter.

Note:

The reason for the power down displays as an on-screen error  message.

Before Using Recovery Commands Before using any of the recovery commands you need to perform the following  procedures. To correct the condition before recovery

1. If the operator console lost power, turn on the main power supply and start up the C-200MT program. Then enable servo power and initialize the cutter. OR  If an EStop occurred, press Enter to clear the message from the screen. Enable servo power. OR  If accidental system power down occurred, press Enter to clear any error message from the screen. Restart Windows NT, if necessary, and restart the C-200MT program. Then enable servo power and initialize the cutter.

Recovery 53

Restore State Use the Restore State feature to return to the last piece and bite that was being cut before a power loss, EStop, or system power down. This feature automatically restores all of the following: •

Reopens the cut file/marker 

•

Restores the setup

•

Restores Fabric Alignment, if used

•

Restores the origin

•

Searches for the piece being cut before the cutter stopped

•

Restores a Job Queue, if open (refer to C-200MT Software User’s Guide)

To restore state of last cut file/marker 

1. Make sure the condition that stopped cutting is corrected. 2. Do one of the following: Press the Restore State key on the keyboard. From the Recover menu, select Restore State. 3. If the marker and piece information displayed in the Restore State dialog box is correct, press Enter or click the OK  button.

Note:

If this information is not correct, you can use the procedure for restoring state manually. See the next section.

The marker is opened and the System Message box prompts that the State is restored. 4. Verify that the correct piece and bite number display in the System Status window. If correct, start processing.

54 Recovery 

Restoring State Manually Instead of using the Restore State feature, you can manually restore state using the following steps. To restore state manually

1. Position the origin light at the top of the bite clip for the last bite cut. Set a new origin. 2. Choose the correct setup to configure your cutter. 3. Open the cut file/marker. 4. Use Piece Search explained in the next section.

Piece Search Use the Piece Search feature to find and cut a specific piece in a cut file/marker. This is useful after an EStop or system power down, especially if the Restore State command does not find the correct piece to cut. To find and cut a specific piece

1. If cutting was interrupted, make sure that the condition is corrected and the marker you want to cut is open. 2. Do one of the following: −

Press the Piece Search key on the keyboard.

−

From the Recover menu, select Piece Search.

3. In the Piece Search dialog box, type to enter the Piece to Search to. Then press Enter or click the OK  button. The File Display area shows the piece in the cut file/marker. The System Messages box reports that the requested piece was found and gives the bite number it was found in.

Note:

When the piece being searched for is split across two bites, a dialog box displays. If you want to begin cutting the part of  the piece located in the first of these two bites, click the Yes  button. If not, click the No button.

Recovery 55 

Piece Recut Use the Piece Recut feature to recut a specific piece in a cut file/marker that might not have been cut properly. To recut a specific piece

1. Make sure the cut file/marker you want to cut is open. 2. From the Recover menu, select Piece Recut. 3. In the Piece Recut dialog box, type the piece number to recut. Then  press Enter or click the OK  button. The piece you want to recut displays alone in the Marker Plot screen. The System Status window reports that the requested piece was found and gives the bite number it was found in. 4. Position material on the table. 5. Position the cutter head near the lower left corner of the area to be cut. 6. Set the origin. 7. Start processing.

Restore Origin Use the Restore Origin feature to restore the origin point. To restore the last origin

1. Make sure the condition that stopped cutting is corrected. 2. From the Recover menu, select Restore Origin . The origin is reported in the System Messages box, where x.xxx and y.yyy are the absolute table coordinates for the restored origin point.

56  Recovery 

Bite Search For conveyorized systems, use the Bite Search feature to find and cut a specific  bite in a cut file/marker. To find and cut a specific bite

1. If cutting was interrupted, make sure that the condition is corrected and the cut file/marker you want to cut is open. 2. From the Recover menu, select Bite Search. 3. In the Bite Search dialog box, type to enter the Bite to Search to. Press Enter or click the OK  button. The System Messages box reports that the requested bite is found and gives the piece number of the first piece in that bite.

Recovery 57 

58  Recovery 

Working with Parameters  Parameter Manager  Use the Parameter Manager command to verify settings and make changes to a setup. When the Parameter Manager screen displays, the first item in the Parameters section (top half of screen) is highlighted. Parameters in the window belong to the category highlighted in the Categories section (bottom half of screen).

Note:

Refer to the C-200MT online help for the latest information on using Parameter Manager.

Rectangle indicates whether Parameters (as shown) or  Categories are currently selected

Range or  choices

To use Parameter Manager 

1. From the Setup menu, select Parameter Manager. 2. To move through the list of parameters, do one of the following: −

Use the arrow keys on the keyboard.

−

Use the pointing device.

3.  Notice that the rectangle at left indicates whether parameters or  categories are currently being selected. To select a different category, do one of the following: −

Use the arrow keys on the keyboard.

−

Use the pointing device.

Working with Parameters 59

4. To exit Parameter Manager, press Esc or click the Close button.

Changing Parameters Use the Parameter Manager to: •

Change parameters temporarily for the current setup

•

Change parameters permanently for one or more setups

•

Create a new setup

•

Determine who can view or change parameters

Refer to the C-200MT online help for the latest information on accessing, changing, and searching for parameters.

Categories of Parameters Parameters are settings that are included in the setup for your cutter. Some  parameters turn a feature on or off. Other parameters define a value within an allowable range. For example, use the Clipping Window Option parameter to turn this feature ON and then set current values using Clipping Boundary  parameters. Categories group parameters that relate to a cutter feature. The following  parameter categories can be accessed at the User and Supervisor levels. Additional parameter categories can be accessed at the Field Service level.

Note:

For a complete list of parameters and information on changing levels, refer to C-200MT online help.

Category

Parameters Used To

Frequently Used Parameters

Provide quick access to frequently-used  parameters; can be customized.

Knife and Drill Speeds

Control knife and drill speed for specific cutting conditions.

Sharpen Parameters

Control how and when the knife is sharpened. Define how the cutter determines wear on the knife blade and when the knife should be replaced.

Cutting Parameters

Control advance and overcut distances and limits. Control cut angle and slowdown  percentage for cutting operations.

60  Working with Parameters

Category

Parameters Used To

Vacuum System

Control the vacuum options.

Ignore Codes

Tell the cutter to ignore or respond to certain marker data codes.

Bristle Cleaner

Control times and number of sweeps for   automatic cleaning.

Knife and Path Intelligence

Control how Knife Intelligence, if available on your system, compensates for cutting forces on knife. Set up Path Intelligence to automatically adjust feed rate for the best cut quality and throughput.

Data Format/Scaling and RSO

Define the format of cut file data or AAMA data conversion. Define X and Y-axis scaling. Define marker size. Initialize RSO cutters.

Bite Parameters

Define how the cutter handles bites. Define end  park position.

Options and Modes

Turn on/off various GERBERcutter features.

Mirror Image and Clipping Window

Turn on the mirroring options which rotate the cut file/marker before cutting. Turn on the clipping window feature and define boundaries.

OPSTOP and Report Options

Control how the cutter responds to OPSTOP codes. Define Cutter Info Database reporting.

Selvage Cut/Contiguous Cut

Control Selvage/Web cutting for vertical line cuts through the selvage or the selvage and web. Control processing of consecutive markers.

System Setup Parameters

Set maximum beam velocities for cutting.

Cut File Preprocessor

Determine the parameters used when  preprocessing markers.

Queue Manager

Determine how Queue Manager handles cut data files.

Security

Determine whether or not Cutter and Notch  parameter tables can be selected and/or edited for  the AccuMark marker currently being opened.

Working with Parameters 61

62  Working with Parameters

Optimizing GERBERcutter  GERBERcutter Along with routine maintenance procedures, such as knife sharpening and bristle cleaning, adjustments need to be made for differences in fabric and spreads. Parameters and menu commands allow you to set up and run these features.

Maintenance Refer to the C-200MT Software User’s Guide for routine procedures on: •

Sharpening the knife

•

Resetting for a new knife

•

Bristle cleaning

Refer to the GTxL GERBERcutter System Service Manual  for maintenance schedules and advanced maintenance procedures. Refer to the Service CD for  parts information.

Applications Refer to the GTxL GERBERcutter Application Manual . Also, refer to the C-200MT Software User’s Guide for procedures on: •

Controlling Cut Speed

•

Adjusting Knife Speeds

•

Changing Feed Rate

•

Controlling Vacuum Levels

•

Using Path Intelligence

Diagnostics/Error Messages Refer to the C-200MT Software User’s Guide for diagnostic procedures and a listing of Error Messages available to assist in troubleshooting your GERBERcutter. Two new diagnostics, listed on the next page, are used with your GTxL GERBERcutter.

Optimizing GERBERcutter  63

Beam Squareness This diagnostic is used along with Beam Square Test to square the beam for cutters, such as GTxL, with two, independent X motors. Use this diagnostic to have the system set a Beam Square Adjustment value based on x1 and x2 index distances. This value needs to be reset whenever: •

Mechanical part(s) affecting x1 and x2 index distances have been replaced or modified

•

Beam has been mechanically squared

•

FEP software has been loaded

Once this diagnostic has been run, the beam is automatically squared when you initialize the cutter, including after EStop or error conditions. Refer to the C-200MT Software User’s Guide for complete information on the Beam Squareness and Cut Tests/Beam Square Test diagnostics.

Dynamic Offset / Yaw Cut Test Use this Cut Tests diagnostic to: •

•

Check offset whenever maintenance is performed on the sharpener or roller guide or if a cut quality or sizing condition exists. Check yaw whenever maintenance is performed on C-axis components or the sharpener.

Refer to the C-200MT Software User’s Guide for complete information on using the Dynamic Offset/Yaw Cut Test diagnostic.

Customer Support If a problem still exists after troubleshooting, call Gerber Field Service Engineering for assistance. In North America, call Customer Support 800-999-1448. Outside North America, call your local service office. Have the following information ready when you call: •

•

GERBERcutter you are using Any special equipment or software you are using, such as the drill, resealer, or bar code reader option

•

Software packages you are using; include the software version numbers

•

Equipment number, if available

64 Optimizing GERBERcutter

Glossary  axis

An imaginary line used to describe movement and location on the cutting table. The GERBERcutter  utilizes three axes: X (parallel to table length), Y (parallel to table width), and C (knife direction). beam

A support and carrier for the cutter head as it moves across the width and up/down the length of  the table. beam control panel (BCP)

A terminal that lets you control the cutter head and beam assembly from the cutting table. The computer  which processes input from the beam control panel is called the BCC. For specific controls available on the BCP for your cutter, refer to the GERBERcutter operator's manual or Getting Started. bite

A section of a marker that (a) fits on the cutting table and (b) can be cut at one time. Bite feeding matches cutter head movement with conveyor movement, permitting automatic cutting of a long spread of material. The spread is cut in sections that fit on the cutting table surface. Each section is called a  bite. BRISTLE SQUARES

Squares of molded bristle that install into conveyor slats or into a fixed grid. They form a work surface for cutting material. C-axis

An imaginary, straight line that the knife rotates about. Cutter Information Database (CIDB)

An optional C-200MT utility that uses a database to track time relative to cutter operation and reports this information. command

A request to perform a function that is entered at a terminal, such as the PC or FEP at the operator  console. Also, an item you can choose in a C-200MT menu in order to use a feature in the C-200MT  program. conveyor 

Moving work surface made from slats and covered with Gerber BRISTLE SQUARES. CTOT

The Conveyorized Take-off Table (CTOT) is a device for moving cut pieces off the cutting table surface. The CTOT is made of plastic links, that move in synch with the conveyor.

Glossary 65 

cut file

A computer data file that tells the GERBERcutter how to cut particular patterns (a marker) out of a spread of material. Also, see marker. data

Information stored on a disk. default

A setting that is programmed into the computer at the factory or set by Field Service when the cutter is first installed. This is used until you or your supervisor override it by selecting another setting. disk or disc

A computer storage medium. GERBERcutter systems can use 3.5-inch disks and CD-ROM discs. disk drive

A device that lets a computer read and write data on a disk. Your cutter has 3.5-inch and CD-ROM disk/disc drives. drill

An optional unit that attaches to the cutter head for making drill holes. dry haul

The distance traveled with the knife out of the material. dry run

To execute a cut file without plunging the knife or drill into the material. EStop

A red push button that can be pressed during an emergency to immediately stop all GERBERcutter  motion. feed rate dial/slider 

Control used to set the desired cut speed. front end processor (FEP)

A computer in the operator console that relays your commands, cut file data, and setup file data to the Motion Control Computer for processing. hard disk drive

A device that holds the software that runs the GERBERcutter. A hard disk drive uses rigid metal disks to store large amounts of data. You need to manage your hard disk so it does not become too full and disorganized. For information on managing files on the hard disk, see File Manager in the Cut File and Report Utilities chapter or refer to documentation for AccuMark Explorer or Windows NT. hardware

Physical elements of a computer, such as the monitor and keyboard.

66 Glossary 

heel cut

Cut made by the heel of the knife. The heel is the thickest edge (following edge) of the knife blade. home

Cutting table's (X0,Y0) coordinates. initialize

To set the cutting table's (0,0) coordinate after downloading the C-200MT software. The system uses this coordinate as a reference when processing a marker. Knife Intelligence

Knife Intelligence® (KI) is a GERBERcutter feature that: •

Senses deflection of the knife (lateral force) caused by cutting difficult materials or high ply spreads

•

Changes knife angle to compensate for this deflection

Note: KI

is not applicable for S-3200, GT 3250, and GTxL GERBERcutter systems.

 job queue

A job queue contains multiple markers or cut files to be cut sequentially. Each marker and its corresponding setup file is called a job. See Queue Manager chapter. limit switch

A switch that sets boundaries (limits) for the travel of the cutting head or beam along the work surface of the cutting table. marker 

Another name for a cut file being processed on the cutter. Also, an AccuMark file that identifies the layout of pieces on a spread for cutting. mast

A tower available with lateral drive GERBERcutter systems that holds the overhead power cables, shop air hoses, and houses a flashing warning light and alarm to alert others when the cutting table is moving. An exhaust stack for the vacuum system may also be located on the mast. motion control computer (MCC)

A computer, or controller board, that responds to instructions sent from the front end processor to control cutting table, beam, and head motion. network

A set of computers connected together. For example, a GERBERcutter may be networked to a CAD grading and marking system. offset

A value by which one item is set or located differently relative to another item.

Glossary 67 

operator console

The location on the GERBERcutter where the C-200MT program is accessed and marker processing is initiated. The operator console includes a monitor, keyboard, and computer with a hard drive, disk  drive, and CD-ROM disc drive. See also Front End Processor FEP. OpStop

A command in a cut file that causes the cutter to stop processing while the operator checks matching  points and slews the cutting head as necessary. origin

The “start” position (X0,Y0) of a marker on the table. This is set at the corner of the marker closest to the take-off end on the side of the cutting table where the operator console is located. parameter 

A setting defined in the setup file. Path Intelligence

Path Intelligence (PI) completely or partially controls cut speed using built-in application knowledge and by measuring one or more of the following: •

Knife sharpness

•

Vacuum level

•

XY force

Use commands in the Diagnostics/Path Intelligence menu to ensure that the GERBERcutter is running  properly. program

A set of instructions for a computer to execute. The programs that direct a computer are called software. right side

The right side of the cutting table as seen from the take-on end. servo motor 

An electric motor used to move the beam along the X-axis or the cutter head along the beam in the Yaxis of the cutting table. setup

A setup is a file containing parameters which enable or disable various features, options, and modes depending on such considerations as ply height, material characteristics, or marker width. software

Set of computer programs used to run the GERBERcutter and communicate with you. These include the C-200MT program and Windows NT. spread

One or more layers of material spread on the cutting table surface for cutting. May also be called a lay.

68 Glossary 

stack

A pipe, mounted vertically, that vents vacuum exhaust away from the GERBERcutter. This is usually mounted on the mast. take-off end

The end of the cutting table where cut pieces and scrap material leaves after being cut. take-on end

The end of the cutting table that receives material for cutting from the spreading table. utility

A program that helps you operate the cutter, such as Queue Manager, Preprocessor, or View Marker. X-axis

A horizontal reference line in a coordinate system. For the GERBERcutter, the X-axis runs the length of  the table from the take-on end to the take-off end.  Y-axis

A vertical reference line in a coordinate system. For the GERBERcutter, the Y-axis runs the width of  the table from the left side to the right side. zone (vacuum)

A vacuum feature that applies vacuum to a certain area of the cutting table. A cutting table with this feature is divided into five or six zones. Vacuum can be applied to one or more zones at a time depending on parameter settings.

Glossary 69

70 Glossary 

Index  A Accessing C-200MT Program ................... ......................25 ...25 AccuMark  open marker or cut data......... data ................... ....................42 ..........42  parameter  parameter tables ................... ............................ ................... ............43 ..43 AccuMatch....................................................23 Air Pressure Gauge......... Gauge .................. .................. .................. ............20 ...20 Applications Applications......... ................... ................... ................... ................... ............63 ...63

B Bar Code Reader...........................................24 Beam...............................................................9 Beam Control Panel (BCP)...........................14 Bite feeding.......................................................35 Bristle Cleaner Options.................................24 BRISTLE SQUARES....................... SQUARES............................... ..............9 ......9

C C-200 Controllers ................... ............................ ................... ...............6 .....6 C-200MT accessing ...................................................25 exiting........................................................51 main cutter control screen ..................... .........................26 ....26 C-axis............................................................32 Circuit Breaker..............................................12 enclosure locations locations .................... .............................. ................13 ......13 cleaning work surface ................... ............................ ................24 .......24 Controls ........................................................12 location on GTxL .................... ............................. ..............chart .....chart Conveyor  controls......................................................17 Conveyorized Conveyorized Take-off Table (CTOT).........31 CTOT auto enable.........................................17 cut file display ................... ............................ .................. ................... ..................30 ........30 open........ open ................. .................. ................... ................... .................. ..............42 .....42  process..................  process........................... .................. .................. ...................49 ..........49 Cutter Head......................... Head.................................. .................. ...................9 ..........9 Cutting  basic concepts concepts ............ ..................... ................... .................... ............31 ..31  basic steps steps ............... ........................ .................. ................... ................38 ......38

Cutting Table components components .................. ............................ ................... .................. ............7 ...7 dimensions ..................................................8

D Diagnostics ...................................................64 Drill Options .................. ........................... ................... ................... ............24 ...24

E Enabling Servo Power ................... ............................ ...............39 ......39 Error Messages Messages ................... ............................. .................... ................64 ......64 Emergency Emergency Stop (Estop) ................... ............................ ............17 ...17 locations ................... ............................. ................... .................. ..............19 .....19  plungers/switiches................  plungers/switiches......................... ................... ............18 ..18 Exiting ..........................................................51

F Feed Rate Slider............................................28 FEP (PC)............................................... ....6, 17 File Display Options.......... Options ................... ................... ..................30 ........30

G Gauges .................. ........................... .................. .................. .................. .............27 ....27 GERBERcutter GERBERcutter Systems Systems ................... ............................ ..............6 .....6 GTxL GERBERcutter.....................................5  ply height.......... height................... .................. ................... ................... ...............5 ......5

H Home.............................................................40

I Initializing Initializing the Cutter.......................... Cutter................................... ..........40 .40

J Jog ................................................................19 controls......................................................20

L Laser Light  position...................  position............................. ................... ................... ................48 ......48 safety.......... safety ................... ................... ................... ................... ................... ........... ix

Index

71

Lateral Drive controls for GTxL......... GTxL ................... ................... .................. .........21 21 option......... option .................. ................... ................... .................. .................. ........... 22 Limit Switches .................... ............................. ................... ................ ...... 11

M Main power circuit circuit breaker .................... .......................... ...... 12 Maintenance Maintenance .................. ............................ ................... ................... ............ .. 63 Marker  display............... display........................ ................... ................... .................. ............ ... 30  process .................. ........................... .................. .................. .................. .........49 49 Marker Origin................ Origin.......................... .................... ................... ........... .. 48 Material Advance Controls .......................... .......................... 19 GTxL ................. .......................... .................. .................. .................. ............ ... 20

O Opening a Cut File/Marker .................... .......................... ...... 42 Operator Console.......... Console................... .................. ................... .............. .... 16 PC ................. .......................... .................. .................. .................. ................. ........ 17 Operator Controls Location................ Location..........................12 ..........12 on GTxL .................. ........................... .................. .................. ........... .. chart Options for GERBERcutters GERBERcutters .................. ........................ ...... 21 Origin ................................................. .... .... 33, 33, 40 restore ................... ............................ .................. .................. .................. .........56 56

P Parameter Parameter Manager .................. ........................... ................... ............ 59 Parameters Parameters .................. ............................ ................... .................. ............... ...... 60 Piece Recut....................... Recut................................ .................. ...................56 ..........56 Piece Search ................... ............................ .................. ................... ............ .. 55 Platform controls .................. ........................... ................... ................... ................ ....... 21 Ply Height maximum......................... maximum.................................. .................. .................. .........5 5 Positioning the First Bite....................... Bite.............................. ....... 40 POWER Processor .................. ........................... .................. ............ ... 23 Presser Foot Adjust ..................... .............................. ................. ........ 20

Q Queue Information ................... ............................. ................... ........... 29

Restore Origin.............. Origin....................... .................. ................... ............ 56 Restore State......................... State................................... ................... ........... 54 manual.................. manual........................... .................. .................. ............... ...... 55 Resealer Option........ Option ................. .................. .................. .................. ......... 22 Rerun......... Rerun .................. .................. .................. .................. .................. ............... ...... 47 Right Side Option Option (RSO) ................... ............................ ........... 22

S Safety............................................................ vii Selecting Selecting Cutting Speed ................... ............................. ............ .. 49 Servo power .................. ........................... .................. .................. ............. .... 39 Settings Options ................... ............................ ................... ............... ..... 27 Setup................. Setup.......................... .................. ................... ................... ................ ....... 41 Information........................... Information.................................... ................... ............ 29 Shut Down................... Down............................ .................. .................. ............... ...... 51 Spread................ Spread.......................... ................... .................. .................. ............... ...... 37 Start .................. ........................... .................. ................... ................... ................ ....... 25 Switches EStop .................. ........................... .................. ................... ................... ........... 18 Limit .................. ........................... .................. .................. .................. ............ ... 11

T Table................. Table.......................... ................... ................... .................. .................. .........7 7 dimensions dimensions ................... ............................ .................. ................... ............. ... 8 Take-off/ Take-on Ends ....................... .... .... 8, 31 8, 31 Trim Cut .................. ........................... .................. .................. .................. ........... 50 Turning on the Cutter ................... ............................. ................ ...... 39 Turning on the Knife Motor Motor ................... ......................... ...... 49 Turning on the Vacuum.................. Vacuum............................ .............. .... 47

U Underlay....................... Underlay................................. ................... .................. ............. .... 37

V Vacuum Assembly .................. ........................... .................. ............ ... 10 Vacuum Flow Diagram ................... ............................ ............. .... 10

W Work Surface .................. ........................... ................... ................... ............ ... 9 cleaner options......................... options.................................. ................. ........ 24

R

X, Y

Recovery  before.........  before .................. ................... ................... ................... ................... .........53 53 Bite Search.............. Search........................ ................... ................... ............... ..... 57 Piece Recut ................... ............................ .................. ...................56 ..........56 Piece Search................ Search......................... .................. ................... ............ .. 55

X-axis .................. ........................... ................... ................... .................. ............. .... 32 Y-axis .................. ........................... ................... ................... .................. ............. .... 32

72

Index 

Operator Controls — GTxL  C-200MT Tool Bar  (hold cursor over button to see corresponding function key)

Beam Control Panel (BCP)

EStop and CTOT Control Panel

Material Advance Control Panel

Circuit Breaker 

Control

Icon

Description

Location

Circuit breakers/ switch

Turns power on or off for controller, servo motors, conveyor, and vacuum.

Beneath operator console (shown) and at take-on end of  table

EStop switches/  paddles

Imm Immediately tely halts lts all all tab table motio otion n.

Beam, ES EStop an and CTO CTOT T Co Control  panels, and Material Control  panels

Knife motor switch

Turns the knife motor on or off.

BCP

Joystick

Moves (slews) the cutter head and beam in the direction of the arrows. (-X, +X, Y, or +Y); the Slew Enable switch must first be depressed.

BCP

Status light

Indicates changes in status, or mode, for   the cutter. The light flashes when the cutter is in Manual Bite or Trim Cut mode or when a controller error occurs.

BCP

Slew enable button

Allows movement of the cutter head and  beam; depress and hold before using  joystick.

BCP

Control

Icon

Description

Location

Laser light button

Turns the laser light at the cutting head on or off.

BCP

Servo power enable button

Turns on power to the servo motors.

BCP

Vacuum

Turns cutting table vacuum on or off.

BCP, F9 function key, and C-200MT Cutter menu

KI Null

N/A for GTxL

BCP and C-200MT Cutter menu

Fabric Alignment

Sets fabric alignment when pressed twice.

BCP and C-200MT Cutter menu

Initialize

Moves the cutter head to the home X0,Y0  position on the table.

BCP, F11 function key, and C-200MT Main Cutter Control screen

Trim Cut

Manually trims the edges of a spread.

BCP and C-200MT Cutter menu

Origin

Sets the current position of the origin light as the origin of your cut file/marker. Marker origin is the X,Y coordinate where the cut file/marker starts.

BCP, F10 function key, and C-200MT Main Cutter Control screen

Start

Starts cutting on the GERBERcutter.

BCP, F12 function key, and C-200MT Main Cutter Control screen

Stop

Stops the current operation of the cutter.

Pause key, C-200MT Main Cutter Control screen, and EStop and CTOT Control panels

Sharpen Knife

Manually sharpens the knife blade one cycle.

BCP, F8 function key, and C-200MT Main Cutter Control screen

CTOT Jog button

Performs a manual CTOT convey.

EStop and CTOT Control panels

Presser foot adjust dial

Adjusts air pressure for the presser foot on the cutter head.

BCP

Air pressure gauge

Shows current presser foot air pressure.

BCP

Feed rate slider

Sets the feed rate at which the cutter head and beam move across the table.

On C-200MT Main Cutter Control screen

CTOT auto enable switch

Stops CTOT movement during either an automatic or manual bite.

EStop and CTOT Control panels

Auxiliary Joystick

Sets the match point for AccuMatch option.

At operator console

Jog switch

Moves material from a spreading table onto the cutting table; turn and hold to jog forward or to reverse.

At Material Control panel

Lateral drive  pendant

Controls movement of the cutter between spreading tables.

At take-on end